Camoplast TATOU 4S ATV User Manual - Introduction

Manual is about: ATV Track System

Summary of TATOU 4S ATV

  • Page 1

    User manual 1099-01-1005 - version b tatou ® 4s atv track system original notice other languages translation available at www.Camoplast.Com.

  • Page 2: Important

    Camoplast inc. 1701, 3 rd avenue grand-mère, (québec) j1x 0e6 canada e-mail : atvtracksystems@camoplast.Com website : www.Camoplast.Com © 2008 ® and tm are trademarks of camoplast inc. All rights reserved. ©2010 camoplast inc. Printed in canada. Important please read carefully each part of this docu...

  • Page 3: Table Of Contents

    Table of contents introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 using the atv with tracks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 hints and tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...

  • Page 4: Introduction

    1 introduction introduction thank you for choosing tatou ® 4s, a camoplast atv track system, (hereinafter referred to as the "system"). You have made the right choice. This system will provide you with all the traction, performance and durability you require for recreational or work purposes and all...

  • Page 5

    2 using the atv with tracks always follow the atv manufacturer's safety rules and regulations regarding, for exemple passengers transportation, maximum loads, ect. It is the driver’s responsibility to follow the recommended schedules maintenance further described in this manual..

  • Page 6: Hints and Tips

    3 hints and tips hints and tips before leaving for an excursion, make sure you have the following within arms reach : 12 mm, 14mm, 16 mm, 17 mm, 19mm and 30 mm wrenches, one axe, one shovel, one tow cable, a lifting jack and one adjustable wrench. Generally, the slower you go, the better the tractio...

  • Page 7: Safety

    4 safety safety this guide uses the following symbols to emphasize particular information : caution: indicates a potentially hazardous situation which, if not avoided, may result in damage to vehicle components. Note: indicates supplementary information. User notice and disclaimer the tatou ® 4s sys...

  • Page 8

    5 user notice and disclaimer the system consists of many moving parts, including transmission wheels. If an object lodges itself or becomes jammed into the system and blocks the track, it is mandatory to stop the engine and the vehicle and apply the security brake before removing object said. By avo...

  • Page 9

    6 user notice and disclaimer capacities allow. Excessive speed remains one of the main causes of severe accidents on atvs. Camoplast is proud to offer atv conversion kits within its wide range of products. Atv track systems are not only reliable, but safe. However, there are risks inherent to drivin...

  • Page 10: Dangerous Situations

    7 dangerous situations dangerous situations when using a vehicle equipped with track systems, it is important to respect the following safety recommendations. As driving a vehicle equipped with track systems is different from driving a vehicle with wheels, it is strongly recommended that the safety ...

  • Page 11: Steep Descents

    8 dangerous situations steep descents warning it is not advisable to change direction during steep descents. This can lead to a serious malfunction of the atv’s steering system and track systems. During a steep descent, it is advisable to keep the handlebar in a forward direction and to begin turnin...

  • Page 12: Warning

    9 dangerous situations descending and being stuck in reverse warning if the rear track systems get stuck in the snow, avoid moving or towing the vehicle in reverse to ease it from its position , as this could lead to a malfunction of the systems. If possible, move it in the forward direction to free...

  • Page 13: Warning

    10 dangerous situations towing a vehicle out of the snow warning if your vehicle must be towed out of the snow, never tow it in the direction in which it sank. Tow the vehicle in the direction of the trail it left as it became stuck..

  • Page 14: Warning

    11 dangerous situations loading a vehicle into and unloading it from a truck warning when a vehicle is being loaded into or unloaded from a truck box, it is extremely important to ensure that the front tracks do not grip the locking gudgeons of the truck’s tailgate as this could cause them to tear..

  • Page 15: Driving Over An Obstacle

    12 dangerous situations driving over an obstacle driving over a steep ridge warning it is not advisable to attempt to drive over an obstacle, such a tree trunk, a big rock or a steep ridge that could lodge itself between the front and the rear track systems and immobilize the vehicle. The best optio...

  • Page 16: Installation, Removal

    13 installation, removal and re-installation installation, removal and re-installation always follow good shop practices. The place where you will be working must be security, clean, bright and well ventilated. If you are to use a floor jack, never use it as a stand. Always use appropriate stands. T...

  • Page 17: Installation

    14 installation, removal and re-installation installation execute all tasks described in installation guidelines of the vehicle model. Then, proceed to adjust the angle of attack, alignment and track tension as described in this manual. Test drive and re-adjust as required. Removal caution: leaving ...

  • Page 18

    15 installation, removal and re-installation at the front: • remove the anti-rotation bracket cover but keep the anchor bracket attached to the anti-rotation device on the track system. Figure 1 leave anchor bracket attached to the stabilizing rod. • remove track systems. • re-install wheels. At the...

  • Page 19: Re-Installation

    16 installation, removal and re-installation re-installation always clean wheel hubs on the atv before installing wheels or track systems. Figure 2 clean wheel hubs. • re-install track systems at the rear and secure stabilizing rod to anchor bracket for rigid axle. • re-install track systems at the ...

  • Page 20: Adjustments

    17 adjustments adjustments angle of attack for front tracks systems to obtain the correct angle of attack on front tracks systems, perform the following : • loosen the nut (1) compressing the spring of the stabilizing rod (refer to figure 3). Figure 3 • set steering handles straight ahead. • tempora...

  • Page 21

    18 adjustments figure 4 • set the nut (2) shown on figure 5 until the flat bar reaches 254 ± 6 mm above the ground. For right hand side, rotating the wrench towards a makes the system rotate towards c while rotating the wrench towards b makes the system rotate towards d (reverse for left hand side) ...

  • Page 22

    19 adjustments • turn the nut (1) until it comes in contact with the spring, then compress the spring by turning this nut 1.5 turns (refer to figure 6). Figure 6 note: in certain rare cases, where the adjustment of the nut (arti- cle 1 on figure 6) compressing the spring, is close to the end of the ...

  • Page 23

    20 adjustments figure 7 basic tuning (front track systems): • an adjustment of more than 254 mm measured with the flat bar, gives easier steering with wobbling effect at high speed. • an adjustment of less than 254 mm measured with the flat bar, gives harder steering and more stability at high speed...

  • Page 24

    21 adjustments angle of attack for rear track systems to obtain the correct angle of attack on rear tracks systems, perform the following : vehicles with rigid axle or trailing arm suspension • loosen the nut (1) compressing the spring of the stabilizing rod (see figure 8). • set the nut (2) to obta...

  • Page 25

    22 adjustments vehicles with independent suspension • loosen the nut (1) compressing the spring of the stabilizing rod (refer to figure 9). • turn the nut (2) until it comes in contact with both rubber damper and bracket (3). Then, compress the rubber damper by turning the nut (2) one turn. • turn t...

  • Page 26

    23 adjustments note: in some rare cases where the adjustment of the nut (1) compressing the spring is near the end of the threaded rod, extend the rod by unlocking the jam nut (item 3 on figure 10) and unscrew the rod to obtain 19 mm max. Of visible threads. Re-tighten the jam nut. Figure 10 basic t...

  • Page 27: Alignment

    24 adjustments alignment the parallelism must be adjusted with the atv on the ground, driving forward on about 3 m and measuring toe in distance.(refer to figure 11). Note: every time the measurement has to be verified, drive in reverse, then, drive forward again on about 3 m. Figure 11 to perform a...

  • Page 28: Rubber Track Tension

    25 adjustments rubber track tension adjust the tension the rubber track by turning the adjusting nuts of the track tensioner. Adjust track tension. A force of 11 kg positioned as shown should produce a deflection of 19 mm (refer to figure 14). Figure 13 the tool 1, used on the figure 14, can be boug...

  • Page 29

    26 adjustments the following table indicates the force (1) applied and the deflection (2) which must occur according to the conditions of use. Figure 14 basic tuning • a higher rubber track tension reduces the risk of “detracking” and reduces drive “ratcheting” (for severe use only). • a lower rubbe...

  • Page 30

    27 installation of a rubber track installation of a rubber track if possible, position the vehicle on a flat and level surface (or on a suitable lift device). Turn off the engine. Proceed as follows : • set rubber track tension to the minimum (refer to figure 15). Figure 15 • remove the two 201-mm w...

  • Page 31

    28 installation of a rubber track figure 16 • install the rubber track (refer to figure 17). Note: compare with the other rubber tracks to find the correct orientation. Figure 17 • re-install 201-mm wheels. • if working on rear track systems, re-install the 133-mm wheels (refer to figure 18)..

  • Page 32

    29 installation of a rubber track note: if possible, modify a screwdriver blade as shown on the picture to facilitate the task of inserting the wheels on their shafts. Otherwise, use a no. 2 phillips screwdriver. Figure 18 • adjust track tension. Refer to ‘rubber track tension” on page 25..

  • Page 33: Break-In Period

    30 break-in period break-in period a break-in period is necessary in order to allow the components of the system to match themselves to each others. During the break-in period (4 hours or 80 kilometers), follow these recommendations : • avoid running under dry and clean conditions. (for example: asp...

  • Page 34: Warning

    31 replacement of a wheel with extractor replacement of a wheel with extractor use tatou extractor # 2000-00-1050 (article 1, figure 19), and the following procedure to make the replacement: figure 19 • remove the rubber cap of the wheel. If the wheel is retaining by a bolt, unscrew it and remove th...

  • Page 35

    32 replacement of a wheel with extractor • place the extractor under the wheel as shown on fig- ure 20 • then screw the threaded rod to remove the wheel . Figure 20 • insert the new wheel on the shaft until it reaches the shoulder..

  • Page 36: Maintenance Schedule

    33 maintenance schedule maintenance schedule for optimum performance and maximum durability, please refer to the following maintenance grid : note: phillips screwdriver. Do not use a brake cleaning solvent to clean the track system. This may damage sealing components and stickers. Warning do not ins...

  • Page 37: Torque Table

    34 torque table torque table storage the best way to store the system is to lay down each frame on its side, away from direct sunlight. Bolt n-m m8 - 8.8 25 m10 - 8.8 50 m10 - 10.9 70 m12 - 10.9 125.

  • Page 38: Wear

    35 wear wear wheel verify the wear of the wheels especially on the interior guidance strip (figure 21). If the internal plastic structure is visible, the rubber coating is worn and the wheel must be replaced (as illus- trated figure 22-2), or when the wear of the wheel’s rolling band reaches a thick...

  • Page 39

    36 wear figure 22 figure 23.

  • Page 40: Track Guide

    37 wear track guide verify the wear of the track guide by measuring the width of the guide. If dimensions of the guide illustrated in figure 24 are lower than 5 mm, at any place, replace the part. If the guidance strip is worn so that the concave shape is no longer visible, replace the part. An over...

  • Page 41: Anti-Rotation

    38 wear figure 25 anti-rotation verify the wear of anti-rotation system, mainly at the ball joint (figure 26) to make sure that it is not seized or extremely loose. Ball joint damage could harm the performance of the track sys- tem. Figure 26.

  • Page 42: Warranty

    39 warranty warranty camoplast guarantees that the new, unused tatou ® 4s system (system) installed by an authorized dealer or distributor is free from any defects in materials and workmanship during the period and in conditions described below. When operating a new tatou ® 4s system, the user agree...

  • Page 43

    40 warranty 5) damage resulting in abusive use, abnormal use, negligence or even a use which does not comply with recommendations of the manual, excess weight or loading, including excessive number of passengers. 6) labour costs, parts and materials related any and all maintenance costs. 7) damage r...

  • Page 44: Troubleshooting

    41 troubleshooting troubleshooting problem potential cause correction to do presence of debris in the system. Remove any debris which could prevent the proper operation of the system severe and localized wear of a wheel ( flat spot) replace the part sprocket or wheel frozen remove the ice/snow build...

  • Page 45: Serial Number Location

    42 serial number location serial number location the following pictures show the location of the serial numbers on the track system frame and rubber track. Figure 27 figure 28.

  • Page 46: Technical Support

    43 technical support technical support if your dealer or distributor is unable to solve a problem related with the system, you may contact the camoplast support team from monday to friday. Camoplast inc. 1701, 3 rd avenue grand-mère, (québec) j1x 0e6 canada e-maill : atvtracksystems@camoplast.Com we...

  • Page 47

    44 ’’ce’’ declaration of conformity ’’ce’’ declaration of conformity ce declaration of conformity we: manufacturer : camoplast inc. Adress : 1701, 3 iÈme avenue grand-mère (québec) canada g9t 2w6 phone : (819) 533-0008 fax : (819) 533-5532 web site : www.Camoplast.Com hereby sole responsability the ...

  • Page 48

    45.

  • Page 49

    46 item # # pièce/ part description qty tatou 4s - my2011 front left & right 1 1001-00-7102 stabilizing rod ass'y, 200 lbs/in 1 2 1008-77-0010 multi hub spacer 1-1/8" ass'y (metric) 1 3 1008-77-0020 multi hub spacer 2" ass'y (metric) 1 4 1008-77-0040 multi hub spacer 4" ass'y (metric) 1 5 1009-00-71...

  • Page 50

    47.

  • Page 51

    48 item # # pièce/ part description qty tatou 4s - my2011 rear left & right 1 1008-77-0010 multi hub spacer 1-1/8" ass'y (metric) 1 2 1008-77-0020 multi hub spacer 2" ass'y (metric) 1 3 1008-77-0040 multi hub spacer 4" ass'y (metric) 1 4 1009-00-7115 inj sprocket, 15 teeth 1 5 1009-00-7116 inj sproc...

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    49.

  • Page 53

    50 item # # pièce/ part description qty tatou 4s - my2011 independent suspension (is) option 1 1000-00-7002 threaded rod, stabilizing rod 1 2 1001-00-7102 stabilizing rod ass'y, 200 lbs/in 1 3 1015-00-7005 bracket anti-rotation (is) 1 4 1015-00-7026 back plate 1 5 1015-05-7005 spacer 5/8", anti-rota...